Real-Time Efficiency – Using Innovative Data Collection Techniques and the Right

KPI’s to Drive Excellence

GLOBALENERGY FORUM

February 20, 2014Houston, Texas

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Welcome

Global Energy Forum

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• Second largest producer of nitrogen fertilizer in the world

• Facility Location: Yazoo County, Mississippi

• Multiple Plants at Facility:

• Other locations: Woodward OK,

Tulsa OK, Courtright CAN,

Medicine Hat CAN, Donaldsonville LA

Port Neal IA

CF Industries

– Ammonia Plant

– Four Nitric Acid Plants

– Ammonium Nitrate (AN) Plant

– Two Urea Plants

– UAN plant

– Dinitrogen Tetroxide

Production

– Storage Facility

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• Management needed a method to consolidate and view real-time

information to rapidly identify, resolve, and avoid problems for

efficient operation

• Stuck in Reactive Mode:

– Management relying on production reports every 24 hours

– Issues identified after the fact -> always in reactive mode

• Lost Production

– Equipment damage/malfunction, operator error

• Resources tied up in “after the fact” investigations

Challenge

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• Problems to overcome:

– How to change from Reactive to Proactive?

– Needed additional ways to collect data

– Avoid IT vs. OT challenges

• Requirements hand-off, discounted from user

• “It’s what I asked for but it’s not what I need”

• Our solution:

– Provide management a method to have a personalized list of KPI’s

– Expand data collection, both automated and manual

– Allow users to see KPI’s in real-time and historically

Challenge

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• Overall solution

– Focused on a combination of OSIsoft and Microsoft technologies to

generate and display KPI’s based on real-time data

– Why PI? Why Microsoft?

• Ten years experience with PI System

• Custom Integrations/Solutions (SAP, SharePoint, .NET)

• PI and Microsoft are the tools needed for the job

• Did not want to learn another product, avoid learning curve

Customer/Partner Solution

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• Self Service Portal

– Flexible enough for management

– Able to identify, create, and edit

their personal KPI’s

– Self-service tools enable minimal input from IT

– Combine Real-time (proactive) with

historical (reactive)

Key Points in Project Execution

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• Data collection

– DCS Data

• Utilized off the shelf OSIsoft Interfaces

– Field Data

• Wireless handheld PC’s for field data

– Correct hardware for environment

– Barcodes used to reduce human error

– Form Data

• InfoPath forms (hosted by SharePoint)

– SQL, Web Services, OSIsoft interfaces

Key Points in Project Execution (cont.)

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• Architecture

– Microsoft

• SQL Server

• SharePoint

• InfoPath

– OSIsoft

• PI Server

• PI Interfaces

• PI WebParts

• PI Analytics

Key Points in Project Execution (cont.)

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Personalized KPI’s

Roll-up

Performance

Indicator

Custom list

of KPI

Parameters

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Personalized KPI’s

Visibility

of KPIs

over time

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Rolled-up Plant Performance

Management

Can See

Cross-Plant

Performance

Over Time

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Self-Service KPI Setup

Users Have

Easy to

Use KPI

Configuration

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• Proactive vs. Reactive

– Real-time Decision Making vs. Troubleshooting

– Continuous Improvement (visibility of KPI’s over time)

• Operational Sustainability

– Reduced Resource Usage

– Reduced Energy Consumption

– Sustained Higher Production

• Management Satisfaction

– Keeping the big dogs happy

Benefits

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• Next Phase

– Utilizing new analytic capabilities of the PI System

– Expansion of calculated efficiencies

– Continue to grow KPI’s into a single plant wide KPI

– Bring KPI data to mobile devices

– Move into Predictive Analytics

• Historical Analysis -> Real-time Visibility - > Predicting

• Past -> Present - >Future

Future

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• Working with Management

– IT and OT working together

– Teach them to fish instead of giving them a fish

• Getting Better Value out of the Technology

– Built using the technologies / capabilities we already owned

– Using PI as a proactive system versus a reactive system

• Continuous Improvement

– Constantly look for changes - data collection, systems

– Watch for anomalies in production/efficiency versus KPI

Lessons Learned